Apparatus for suspending insulating walls and ceilings



Sept 25, 1934. A. Ee. KOERNER 1,974,819

APPARATUS FOR SUSPENDING INSULATING WALLS AND CEILINGS Filed Feb. 25, 1952 5 Sheets-Sheet l f1 2921223 k1" Y* i7, lQV@ 20262119\ 0 i g WWW@ Z1 @m M Sept. 25, 1934. A. B. Kor-:RNER

APPARATUS FOR SUSPENDING INSULATING WALLS AND CEILINGS Filed FeID. 25. 1932 3 Sheets-Sheet 2 SPt- 25, 1934- A. B. KoERNl-:R 1,974,819

APPARATUS FOR SUSPENDING INSULATING WALLS AND CEILINGS Filed Feb. 25. 1952 3 Sheets-'Sheet 3 Patented Sept. 2 5, 1934` UNITED STATES APPARATUS Fon SUSPENDING INSULAT- `ING. WALLS AND canariosY Albert noemer, Camden, N. J.

Application February 25, 1932, Serial No. 595,128

1o claims. (ci. 'zz- 118) My invention pertains to the hanging of ceilings or side walls of sound absorbing, temperature resisting, and like insulation material in rooms that have either been completed or which are in the course of construction.

A purpose is to mount blocks of sound absor ing, temperature resisting, or like insulating material upon bracketswhich preferably are carried by aligning bars or strips.

A further purpose of my invention is to provide block-sustaining bars or strips which are secured to the ceiling or side walls of the room to be treated, at convenient intervals .which need not correspond to block dimensions and coacting clip or bracket members which are secured to the bars or strips atpne point and to the material to be suspended at another.

A further purpose is to provide insulating blocks with suitable grooves within which clips or brackets engage'.

A further purpose is to provide aligning devices to fit within the grooves in the blocks, and to close the openings between the blocks against air seepage. v

A further purpose is to provide pointed projections on the clips or brackets which are forced into the edges of the blocks for the purpose of holding the blocks in suspension or spacing and supporting them.

A further purpose is to provide a clip or bracket so formed as to engage a supporting bar or strip at one point, to provide an aligning projection at another and at the same time to fit within the edges of two adjacent blocks.

I have preferred to illustrate my invention by a few only of the many forms in which it may appear, selecting forms which are practical and effective but which have been chosen primarily for their value in illustrating the invention.

Figure 1 is an underface view of a fragment of a ceiling composed of insulating blocks and suspended by my devices.

Figure 2 is a top plan of the same fragment illustrated in Figure 1. I

Figure 3 is a section through a plurality of insulating blocks as applied to a room, and taken on a line corresponding to 3-3 of Figure 2, the supporting clips or brackets being 'shown in elevation.

Figure 4 is a perspective view of a fragment of a supporting bar or strip.

Figure 5 is a perspective view of a clip or bracket used in the assemblage.

Figure 6 is asimilar view of a modification of the clip or bracket shown in Figure 5.

Figure 7 is an enlarged section showing a part of Figure 3. i

Figure 8 is a perspective view of one of the 80 insulating blocks.

Figure '9 is a perspective view illustrating an alternate form of block.

Figure 10 is a fragmentary plan view similar to Figure 2 illustrating the character of clip or 65 bracket employed in hanging the block illustrated in Figure 9.

Figure 11 is a section similar to Figure 3, illustrating the clips or brackets employed in connection with the hanging of the type of block shown in Figure 9, the clips or brackets being shown inY elevation for clearness.

Figure 12 shows a detailed perspective view of a clip or bracket used in hanging the block illustrated in Figure 8, when supporting ceiling structure such as that shown in Figure 11.

Figure 13 is a fragmentary perspective view illustrating a modified form of foot for the bottom of the clip or` bracket shown in Figure 12.

Figure 14 is a detailed perspective view illustrating a form of clipor bracket used in hanging a block such as illustrated in Figure. 8, when covering the side Walls of a structure such as that shown in Figure 11.

Figure 15 is a perspective view of a form of clip or bracket used in hanging the type of block illustrated in Figure 9, in the structure shown in Figure 1l.

Figure 16 'is a perspective View of a section of an aligning strip and air stop used in association with the type of block illustrated in Figure 9.

Figure 17 is a perspective View of a modified form of clip or bracket wherein the clip is integral with the supporting element.

Figure 18 is a front elevation of another form of clip or bracket used in the suspension of the -wall blocks.

Figure 22 is a sectional View4 illustrating an 105 application of-the form of clip or bracket shown in Figure 21.

Figure 23 is a perspective view of a clip intended to be inserted between the edges of two adjoining blocks to retain the blocks in alignment. 110

` building is being constructed.

Referring now to Figures 1, 2 vand 3, 15 indicates the plastered' ceiling'of a room having side walls 16, 16. Bars or strips 17, shown as substantially Z shaped in cross section, are made fast to the ceiling by expansion bolts 15 or any other suitlis accomplished by forcing 'pointed right angle able means, for example extending through holes A17', the bars. or strips being spaced at regular predetermined'intervals across the room to coincide with the sizes of the blocks.

lClips or brackets 18 arethen hungon the lower flanges of theZ bar and attached inthe side or edge walls 19 of insulating blocks 20. The latter extensions 21 of the clips or brackets into the edges 19. The insulating blocks 20vare composed of materials which readily permit this insertion. lBecause the bars or strips perform supporting functions which differ in the ceilings from the functions in the Walls in that there is a hanging or depending support only in the ceiling but a laterally extending bracket action in the side walls, I have preferred to call them generally carrier strips to cover both. The clips or brackets also perform slightly different functions in the ceiling and side wall use, but in both of these uses part of the clip or bracket, if not all of it, performs bracket functions. For this reason, notwithstanding that clip functions are performed I have preferred to call them brackets intending to include all of the forms in this term.

At the tops the brackets 18 are turned laterally to produce right angle extensions 22 and 23 extending oppositely in divergent directions from the body portion of the bracket.

The extension 22 is slightly higher than the extension 23, and is adapted to slide over the lower horizontal extension 24 of the carrier 17, while the extension 23 is intended to lie flush on top of the insulating block 20 and act as a gauge for the' attachment of the block, as clearly illustrated in Figures 3 and 7.

One form of bracket 18 is illustrated in perspective in Figure 5, and a modified form 18' in Figure 6. 'Ihe only difference in these two forms is in the number of pointed projections, otherwise they are the same, and function, exactly alike.

In treating the ceiling of a room the work is started at one side of the ceiling and progresses across the room until the opposite side is reached.

The carriers 17 are fastened to the existing ceiling by means of expansion bolts or any other desirable fastener, the free bottom edges of different carriers being spaced equidistantly across the ceiling.

The first carrier at the starting side of the room, is reversed as shown at the left hand side of Figure 3, so that its free flange 24 extends in a direction opposite to the free flange extension 24 of the adjoining carriers. The brackets 17 are either shorn of their extensions at one side (or originally made without them) as indicated at r182 'and arev placed over the lower free edge of the carrier prior to fastening it in place.

One edge of each of the blocks 20 is now forced about the projections 21 of the brackets 182 and driven home until this edge makes contact with,v

the wall. The top face of the block is now ush with the under face of the depending portion of the rst two carriers 17, and a row ofbrackets 18 (preferably two brackets for each block) is posi,- tioned along the edges 19 of the blocks, 'their right angle extensions 22 overlapping the lower extension of the bar 17, and their lprojecting points 21 /on the same side being wedged into the outer free edges 19 of the first row of blocks 20.

'I'he next succeeding row of blocks is now put in place, the upper faces of the blocks being positionedunder the extensions 23 on the brackets and the extensions 21 are forced into the edges 19 as was the preceding row.

This operation is continued across the entire room, the bracket projections 22 being placed over the lower extensin of the carrier and the pointed projections 21 being forced into the body of the block at the edges 19 to support them. At the side wall where the last block is placed, a spacing strip 25 is fastened in the corner and the last row of blocks is positioned against it. This last 4row is finallyd secured in position by the application of the moulding 26, which is carried entirely around the room as a finish.

When it is desired to cover the side Walls with the insulating blocks, the carriers are fastened to the side walls just as they are fastened to the ceiling, the outer free edge being placed so that its flange points upwardly toward the ceiling. This is indicated in the drawings in Figure 3 and is shown in dot-and-dash lines at the left of the figure and against the side wall 16.

The clips 18 are used in the same manner as in the ceiling installationf the extensions 22 being hooked over the free ends of the carriers and the two way extensions 21 being embedded in the edges of the blocks while the extensions 23 form a guide for the placing of the blocks.

In the installation of new work, i. e. where the building is in the course of erection and prior to plastering, the form of clip varies to accommodateJ the slight change in conditions. Illustrations showing this form of structure are best seen in Figures 9 to 16.

In this form I not only save the work of plaster ing, but no lath need be applied to the lathing channels. The insulating block itself forms the ceiling and side wall of the room. i These blocks can have a pleasing surface and be furnished in any tint, thereby eliminating the necessity of papering or painting or otherwise treating when used in rooms requiring decorating.

Supporting beams are indicated at 27 to which are fastened plastering channels 28 vas in the usual form of construction employing metal lath. In place of fastening metal lath to the channels, I hook brackets 29 over their tops. These brackets are designed to'extend about and beneath the upper flange of the channel, resting at 30 on the top of the flange, and hang downwardly at 31 to engage against the broad face of the channel. The hook portion of the bracket is indicated at 32. The bracket carries right and left hand, pointed, right angle ngers 33, which may be in the form of tines or prongs adapted to be forced into the edges of the blocks in the same manner as the extensions 2l.

I further provide right and left right angle projections 34 which act as gauges, the same as j ginning at one side of the room (in the present showing the left) the first channel is reversedV and the fingers (prongs) on that side of the bracket away from the' hook are removed. The

edges of the blocks are forced into the prongs of the series of brackets hanging fromthe first channel and the left hand prongs on the'rowrof brackets' hanging .from the second channel are forced into the adjacent edges of the same row of blocks. The second row of blocks are next put in lplace byforcing the edges of their blocks into the right hand prongs of the clips on the second channel, and bringing the brackets on the third channel into engagement to hold the opposite edge of that, the secondrow of blocks.

This operation is continued until the entire ceiling has been covered; the last rowv of blocks being spaced by a strip 35 and held finally in place by the'application of a moulding 36. In each case vthe projections 34 act as gauges to determine the position of the blocks with respect to the brackets.

The clips are illustrated in perspective in Fig- -ure 12, and an alternate form of foot is shown in Figure 13, at 33'.

When it is desired to apply the blocks to form side walls, I fasten the channel irons 28 direct to the studding 16 of the rooms and hang therefrom a slightly modifledform of bracket 29' as illustrated in Figure 14.` This bracket hooks over the channel the same as the form seen at 29, and has the same vertical body portion. Its main difference is the right angle fingers 292 at the bottom of the vertical portion which endin upward terminals 293, This forni includes one or more sharp prongs which are adapted to be forced into the bottom edge of oneof the blocks 20 to hold the block in place upon the finger at the same time it is being supported by the finger.

A prong 37 is struck out from the vertical wall of the bracket and the block is forced about it until the prong is entirely embedded in the block, thereby offering additional retention means for the block-20. i

An application of this type of bracket is shown a in dot-and-dash lines to form a portion of the left wall of Figure 11.

In Figure 9 I have shown a type of block 20' which is similar kto the block 20 previouslydescribed but with the exception that vit has a groove 38 formed or cut in the edge ,and running completely around the block. When using this block' I employ the form of bracket 39 illustrated in Figure 15. 'This bracket is identical with the bracket 29 except that the ngers 294 have square ends, are without points, and are adapted to t within the grooves 38 of the block 20'. l The blocks are thus hung by the brackets and depend upon the positioning of the grooves in the through the joints between the blocks. The strips 40 are positioned so as to lie half in one block and half in the adjoining block and are run in both directions of the room, thereby closing the lateral as well as the longitudinaljoints between the blocks. At each end of the strips 40 which run in the direction of the brackets, the strips abut against the edges41 or 42 of the brackets 39.

applied to the blocks to form a wall.

`Figure 17 shows a further -modificatibnlof4 a supporting clip at 183, wherein the clip is made integral with the supporting or Z bar 172. In this case the Z bar -is not continuous, but is the same kwidth as the clip, and each clip has provision for vnailing to the ceiling or side walls.

In the form of my invention shown in Figures 18, 19 and 20, I show another wall clip or bracket which has the same function as that illustrated in `Figure 14; but here all the retention projections enter the edges ofthe blocks and none enters the face as in Figure 14. In this design the clip or bracket is-stamped or otherwise produced from a single piece and comprises a body 43, having at its upper extremity a hooked portion'44 identical with the hook 32 in Figures 12, 14 and 15. About midway of the body portion- 43 and at each side are located iingerrests 45 which terminate in upwardlyI extending pointed projections 46.

After the fingers 45 have been turned out a depending section 43 of the body portion 43 remains which extends below the fingers and resemblesA a dovetail in outline. ,v

Struck from the center of the body portion is a finger 47 which terminates in a downwardly extending pointed projection 48.

Figures 18 and 19 illustrate a front view and side elevation respectively of the clip or bracket ready for use, and Figure 20 shows the bracket In this last view the supporting channels are fastened to the studs the same as in the forms shown in Figures 3 and 12, and the clips or brackets are in order to enter and hold the block below.

In assembling a wall the first channel is positioned at or near the floor line. The lower dovetailed portions 43' are then removed from the clips or brackets intended for therst course, as are the fingers 47 and their pointed extensions 48. The brackets are then hung over the channel rails at the required positions with the fingers 46 resting at ornear the floor.

In the 'rst course the blocks are .then forced into place, the upwardly projecting extensions 46 being embedded in the lower edges of the 130 blocks. The u'pper block edges of this first course are moved under the fingers 45 of the clips or vbrackets hanging from the next channel above,

and are forced back until the rear block faces contact with the depending portions 43', against which they rest. The fingers 47 are then struck with a hammer or other suitable tool and caused to move down until they are flush with the top edges of the blocks and their pointed projections 48 are embedded in the blocks.

1 The blocks of the rst courseare now held at their bottoms and at their tops. Shouldit be desired to fasten themA at their side4 edges, I provide a clip such as is illustrated at 49 in Figure 21. This clip is substantially diamond shape having point 49' at one end, and a point 492 at the opposite end. A tongue 50 is struck out from the body of each clip to form a stop to limit the distance to which the clips can be inserted within the edges of the blocks. When of the second block and with the tongue 50jI used as side edge retention members, one

'I'he next vblock is then forced against the second point until it is entirely embedded within the edge lying between. the two blocks, and so on.

As many of these side edge clips 49 as desired can be employed to hold the blocks in alignment.

When the first-course of blocks has been positionedentirely around the room, thel second 'course is started. The lower edges of the blocks of this course are forced about the pointed extensions 46 of the clipsbr brackets handing upon the 'second channelI bar to secure them at their bottoms, and are brought into contact at their tops with the depending ends 43 of the clips or brackets hung from the next channel supporting bar above. 'Ihis second row or course is then made fast at its top by moving the pointed projections 48 downward and into thev top edges. ,Side edge interlockings by means of clips 49 -are made at desired points during assemblage.

The blocks are built`up in successive rows and hung from the supporting channels by the clips or brackets until the entire wall is completed and the blocks of the last row are supported -with their upper edges adjacent the ceiling blocks. The rear face of each block bears against a spacing strip 51 to align the last course perpendicularly. This strip 51 could also be used as a support for the blocks of the first ceiling row if desired.. Suitable molding is applied around the entire room at the ceiling line as in Figures 3 and 11 as a finish at this point, while the floor line'can be faced with a suitable base molding as in anyflnished room.

In Figure 22 I have shown a clip or bracket 52 which is quite similar to clip 18, Figure 5. The clip 52 has top lateral extensions 53 and bottom pointed lateral extensions 54. The upper extensions 53 are apertured at 55 for the reception of nails or other fastening devices to permit of their attachment to a strip of wood 56 (Figure 23). The wood strips are an alternative for the Z bars 17 or channel supports 28. In each case the lower pointed extensions' are out of line with the upper extensions to permit access to the latter for purposes of nailing.

In application of the type shown in Figures 22 and 23, the strips 56 are first made fast tothe ceiling and spaced to accommodate the joints of the various blocks. Clips 52 are now fastened to the strips which are to receive the initial blocks. .The blocks are next forced in place against the projections and the-clips of the second series are then forced into the outer free edges of the blocks and are fastened tothe strips 56. y Row after row is thus added until the ceiling or wall is .completed. This design of clip or bracket lends itself admirably to the application of blocks in patterns or mosaic effects, especially when assisted by the form of clip illustrated in Figure 21.

As will be observed in any of my arrangements of blocks, they do not lie adjacent the walls or their supports, but are held a suilicient distance therefrom to create an air space between the rear of the blocks and the adjacent ceiling or side wall. This air space acts as an additional insulator, assisting the blocks in their retardation of the passage of sound, vibration andheat.

It will be evident that the blocks making up the exposed surface of the wall are normally sup- K point vof each clip is inserted into a block edgeruntil the tongue is flush with the edge.

ported by the brackets or clips in such a way that no portion of the brackets or clips are exposed at the finished surface of the wall. The lateral attachment of the brackets or clips to the blocks firmly engages the blocks on both sides of an individu'al bracket or clip, preventing relative movement of the blocks toward or away from the wall support and also supporting the blocks against'movement longitudinally of the wall in either direction.

'Ihe blocks normally have suiiicient resilience so that the slight tendency of the brackets or clips to'space adjoining blocks is overcome, and the adjoining. edges of the/blocks'are in tight contact, leaving no crack between adjacent blocks. Where the blocks lack in resilience, I ymay of course groove the edges to receive the brackets or clips. The preferred applicationof my invention, although by no means the only one in which it may be used, is for the construction of sound deadening walls (either side wallsl or ceilings).

For this purpose, the wall itself must be soft and resilient, and it is therefore of course not possible to plaster or otherwise apply a coating to -deadening properties. It Vwill be therefore evi-4 dent that the supporting means of vmy invention permits the blocksto'be exposed to view in the finished room, without the necessity for exposed portions of the supporting means beyond the blocks, nailing or even toe nailing through the blocks or making screw or glue attachments to the blocks.

In( referring to a wall, I intend to include both a side wall and a ceiling, and in referring to a wall support I mean to designate the structure within a wall, whether a side wall or a ceiling. l

In view of my invention and disclosure variations and modifications to meet individual whim or particular need will doubtless become evident to others skilled in the art, to obtain part or all of the benefits of my invention without copying the structure shown, and I, therefore, claim all spirit and scope of my invention. f

Having thus described my invention what Il claim as new and desire to secure by Letters Patent isz- `1. In a wall, a wall support, a plurality of laterally spaced bars fastened to the outer face of the support and presenting outer faces outwardly spaced from and generally parallel to thevsupport, a block against the bars and having its finished face in position to form a portion of the intended wall and spaced from the wall support sufliciently to leave a dead space between the wall support and the block, and clips or brackets securing the blocks against the outer faces of the bars and having integral outer ends'embedded in opposite edges of the block, the said clips or brackets having lengths less than that of the abutting block edges and being wholly inwardly of the outer face of the block.

2. In a wall, a wall support, a Z bar secured to the wall support and extending parallel to the surface ofvthe intended wall, a block having its finished face on the line of the intended wall and its inner face against the outer face of the Z bar and a clip or bracket engaging the bar on the inside of the outer flange thereof, extending out from it and having a nger near its outer end and nteral therewith embedded in the edge of the 3. In a wall, a wall support, a plurality' of laterin the saidrlateral direction substantially equal to the said spacing of the bars, land clipsV or brackets hooking to the bars, ,extending from the bars to between the edges of adjoining blocks and having y fingers near the outer ends of each clip or bracket embedded in the abutting edges of adjoining blocks, the said clips or brackets being wholly inwardly from the outer surfaces of the blocks permitting the blocks to present a finish wall surface at the time of erection. y

4. In an insulating Wall, supporting bars fastened directly to the wall and running the length of the surface to be insulated, a plurality of clips or brackets suspended from the bars, extensions from the bars for receiving extensions from the clips or brackets, the extensions of the bars and clips being located longitudinally of each other and extensions adapted to lie betweenthe edges of adjacent insulating blocks, and to enter the edges to support the blocks, and insulating blocks held by the clips or brackets, the clips or brackets being invisible when viewed from the face comprising the Vfinished surface of the supported blocks, and the clip or brackets having lengths less than that of the said abutting edges of the blocks.

5. In a support for insulating blocks, supporting bars fast to and running the length of the surface to be insulated, clips or brackets suspended from the bars and adapted to lie between the edges of adjacent insulating blocks and projections on the clips or brackets, integral therewith, some entern1 ing a peripheral slot in one block and others entering a peripheral slot in the adjacent block at points back of the face thereof, and the clip or brackets having lengths less than that of the said abutting edges of the blocks.

6. A support for insulating blocks, comprising a bar running the length of the surface to be insulated, brackets carried by the bar and movable thereon, finger projections extending outwardly from the body of the bracket, pointed extensions on the lingers lying in a plane parallel to the body of the bracket and adapted to enter the edge of.

the insulating blocks, and pointed projections formed from the body portion of and extending at right angles to the body portion of the bracket and adapted to enter the rear face of the insulating blocks.

7. In a support for insulating blocks, a bar running the length of the surface to be insulated, and a bracket carried by the bar and movable thereon, and comprising a body portion, a substantially Vhook head portion and pointed substantially right angle projections formed integral with the body portion and adapted to enter one face of the insulating block.

8. A support for insulating blocks comprising a bar running the length of the surface to be insulated, brackets supported by the bar, nger projections extending outwardly from the body of the bracket, pointed extensions terminating the finger projections and a second finger projection extending outwardly at an angle from the body portion and terminating in a pointed extension, the latter extension being adapted to be forced into a right angle position with respect to the body portion.

9. In a wall, a block having a peripheral slot between its front and its rear faces, a plurality of hangers on opposite sides of the block, narrower than a side of the block, each having a projection extended behind the rear face of the block, adjoining blocks having peripheral slots and other projections from the hangers extended into the peripheral slots of theadjoining blocks and ex tended behind the rear faces of the adjoining blocks and means for securing the hangers in position.

l0. In a wall construction for a building, a plurality of blocks one beside another having flat sides in abutment, and having peripheral slots extending entirely Varound each block in arplane between the front and the rear surface of each block, hangers extending between the side surfaces of abutting blocks having projections into the slots of adjoining blocks on opposite sides of the hangers and at the inward ends of the hangers whereby the hangers are not visible on the finished face of the Wall, each hanger being narrower than the side of one block, and means for securing the hangers to the permanent structure of the wall.

ALBERT B. KOERNER. 

